Modular architectural construction system comprising universal interconnectable parts

ABSTRACT

This simplification in the manufacturing process results in a simplification of the infrastructure of our installed plant capacity.

FIELD OF THE INVENTION

The invention pertains to prefabricated construction. More specifically,the invention pertains to modular construction.

DESCRIPTION OF THE RELATED ART

The modular construction system described in this document differs fromthe system developed in patent 7695 in that another connector concerningpatent 7695 is used. This is basically a connector that allows thesystem to work with an artificial floor (11) and not necessarily with aconcrete slab, and at the same time it allows for building two floorswith the kit's double-size connector (12), and then this structure thatadds the universal wall panels of patent 7695 may be assembled, but withsubstantial improvements in its characteristics until a second floor isbuilt. There are supporting parts for the artificial floor structure(15), which is additionally a different way to build the universal wallpanel (1) based on patent 7695, which now allows for changing the doorfrom right to left or vice versa, as well as the window, without theneed to turn the wall panel around, as in patent 7695. However, it isconsidered to be the same universal wall panel of patent 7695 butimproved with certain advantages for internal production, and at thesame time it is added the fact that to make this wall panel parts (2),(3), and (4) (FIG. 1) are built to make the universal wall panelsdescribed in FIGS. 1 and 2, which finally make up the same wall panel,also considering the electrical circuits, but not the water pipes.However, this facilitates production.

DESCRIPTION OF THE INVENTION

The modular construction system or process of the present utility modelapplication makes the construction of prefabricated houses simpler, morepractical, and allows for the assembly a second floor, unlike patent7695 (FIG. 23). In addition, this system or process provides a reductionin operating costs. Said procedure consists of the following components:WALL PANELS, SINGLE-SIZED AND DOUBLE-SIZED CONNECTORS, A UNIVERSAL WATERBOX SYSTEM, AND LOCKING ANGLES for assembly. They all are completelyidentical to one other, that is, each component has a unique or standardshape, in order to optimise the process and facilitate mass production.The characteristics of the construction system that is intended to bepatented herein are described below:

a) Universal Wall Panel

The wall panels have the distinctive feature that they are all identicalto one other, as in patent 7695. However, the improvement lies in thatthis wall panel is at the same time formed of sub-products or partswhich are also universal. This allows for quick assembly and is animprovement or refinement of patent 7695, that is, universal from itssub-products, and there is also exterior and interior finishing, as wellas the ability to include a door or window by optionally removing theswitch box (4)/outlet, among others. Furthermore, each one of the wallpanels contains a circuit wiring inside, which allows for universalityin all of the wall panels.

This wall panel is a standardised part that is made from universal boxes(2,3, and 4), which allows for faster production than the wall panel inpatent 7695 but has the same function. Another feature that makes itmore versatile is that the built-in water system is now removed and hasbecome another universal part of the kit, since now it is easier tobuild the wall panel and also to add the water system as two separatecomponents. In the case of electrical conduits of two-storey buildings,the conduit cannot go through the wall connector in the first floorsince the wall connector may lose structure. Then, for the wall panelsof the first floor, the electrical conduits shall go above the wallconnector, always inside the structure and always in the upper part ofthe wall panel as in patent 7695. In the upper wall panels, it ispossible to make the built-in electric links go through the connector,thus optimising the installation speed in the second floor. Furthermore,this wall panel is universal and used to completely assembly theprefabricated house models and other structures for different purposes,that is, the wall panels are universal or standard; therefore, it ispossible to connect a wall panel with another wall panel through auniversal connector and always fit one another. In addition, the wallpanels already structured to allow for the correct functioning ofelectricity for all of the houses. In this regard, not only does thewall panel have holes, but also water pipes and electrical conduits, aswell as switches, outlets, among other things, in addition to doors andwindows, which shall have a fixed position (by default) on allmanufactured wall panels. All wall panels are sized 2.40-m high, 3-mlong, and 10-cm thick. All power, water and drainage connections arepre-installed and can be used or left unused as needed. This approachallows for mass production and optimal manufacturing speed.

b) Universal Wall Connector (11)

This connector differs in that it is a dual connector, acting as a kit.This second double-sized connector (12) is used to build the secondfloor. This connector consists of a square tubular structure, with holesin fixed positions that allow for the synchronised assembly of thestructure so that by using this connector plus the double-sized one itis possible to tie up the floor grid, the columns of one and two floors,and the perimeter frames to finally build a single-sized part, exceptfor the double-sized connector. There is also the possibility ofremoving the entire upper grid, either in the ceiling of the secondfloor for that case, or in the upper grid in the case of one-storeybuildings. This possibility becomes obvious and simple since the wallconnector is designed for said purpose, so the two options are jointlyoffered.

c) Universal Water System (20)

This part (20) of the system kit (FIG. 24) is a box that houses or holdsa cold-water pipe network and a hot water pipe network in parallel form,where the upper pipe (21) has an outlet downward diversion on the leftside, which is used as network supply; and the lower pipe (22) has thesame arrangement, but the other way around. This system is designed tobe coupled to the wall panel and also has 4 outlets that go into thewall panel (23). These outlets have threaded “tee” ends ready to insertsome nipples which are also threaded and shall go through the wallpanels in case it is required to use this part. This water system partis also universal and meets any need.

BRIEF DESCRIPTION OF THE DRAWINGS

Please note that in order to illustrate explanatory figures in thisdocument, it was decided to use certain materials as an example. Thisdoes not specify at any time that the system described herein only workswith the materials possibly indicated in some figures. In this system orutility model, it does not matter what material is used formanufacturing. The important thing is that it works correctly.

FIG. 1: shows a universal wall panel with a different internal structuredeveloped with universal boxes (2, 3 and 4), which allows for a highermanufacturing speed and also allows for changing the position of thedoor from right to left and vice versa by removing the box (4) andwindow.

FIG. 2: another embodiment of wall panel with a door (9) and window (10)instead of boxes (4).

FIG. 3: shows an embodiment of the wall panel wherein two parts areremoved and replaced by a door in this case.

FIG. 4: another embodiment with two windows (10) replacing two parts orboxes (4) in the wall panel (1).

FIG. 5: the same wall panel in front view showing composition ofuniversal boxes (2, 3, and 4), improved power circuit (6) in the boxes(2) that make up the wall panel and upper tie-down strips (5) that makeup structure for the wall panel, and a bottom tie-down strip having thesame function (8).

FIG. 6: shows a wall connector (11) and its two opposite sides (11.1)and (11.2).

FIG. 7: shows the wall connector plant view, where a square section andsides (11.1) and (11.2) that are opposite to each other can be seen.

FIG. 8: shows position dimensions of connector holes on sides (11.1) and(11.2) respectively.

FIG. 9: shows a double-sized pipe having two opposite ends (12.1) and(12.2) with a length difference of 5.40 metres.

FIG. 10: shows the same double-sized wall connector and its two oppositesides (12.1) and (12.2).

FIG. 11: shows an assembly embodiment of wall connectors (11) and (12)in front view, where the position of sides (11.1) and (11.2) as well asthe sides of the double-sized connector (12.1) and (12.2) are shown.

FIG. 12: shows the bolt inserting angles (13) that tie the connectors ina typical way to any fastening points.

FIG. 13: shows another angle (14) with a small variation in the positionof the holes (14.1), identical on both sides of the angle.

FIG. 14: shows long angles (15) with two sides (15.5) and (15.2) to fixfloor parts (17) (18) (19), shown in FIG. 16.

FIG. 15: shows an embodiment wherein the connectors (12) are locked infor two floors and a typical embodiment (11) for one floor through anangle (13).

FIG. 16: shows typical floor parts for fixed orthogonal spaces whichalways have the same shape in this system.

FIG. 17: shows the box (2) assembled by the wall panels, in perspective.

FIG. 18: shows the same box (2) broken into its parts (2.1) (2.2).

FIG. 19: shows the box (3) assembled by the wall panels, in perspective.

FIG. 20: shows the same box (3) broken into its parts (3.1) and (3.2).

FIG. 21: shows an optional box 4, in perspective, that can be replacedby doors or windows as required.

FIG. 22: shows the same box, broken into its parts (4.1) and (4.2).

FIG. 23: example of embodiment with double-sized wall connectors (12)and single-sized wall connectors (11) with wall panels (1) on the outerside of the building.

FIG. 24: shows the water system (20) part where two pipes, one for coldwater (21) and the other for hot water (22), and their respectiveoutlets for the wall interior with tee (23) ends, and the sidesindicating where the water is taken in are shown. A section of aperspective on the other side of the box going to the outer side is alsoshown.

DETAILED DESCRIPTION OF THE INVENTION

The modular construction system of the present invention consists ofwall panels (1), single-sized connectors (11) and double-sizedconnectors (12), water system parts (20), universally enabled floors(17) (18) (19), floor supports (15) and angles with predetermined holes(13) (14), that is to say, they are all completely identical to oneanother, fit together in a complementary manner, and are characterisedby:

a) Wall Panels (1)

The wall panels have the distinctive feature that they are all identicalto one another, that is, universal, and internally consisting ofuniversal boxes (2) (3) (4) with exterior and interior finishing, aswell as a section for a door (9), window (10) by removing the box (4) inthat case, switches (7), among other things. Furthermore, each wallpanel contains electrical conduits (6) embedded inside which allows forperfect fitting to the other wall panels (1), as well as the water pipesthrough the new universal part of the water system network (20). Itmanages to have a greater number of power points (7).

This wall panel (1) is a standardised part made to use the same wallpanel to completely assembly several models of prefabricated houses,that is to say, these wall panels are universal; therefore, it ispossible to connect the wall panel to another wall panel (through auniversal connector), and for it to always fit, in this case, auniversal electrical conduit already structured to allow the correctoperation of services (power and water) for any house.

The wall panel works on the first floor, making a small cut at the timeof installation to prevent hitting the angle (13) (14) and provide theconnector with a supporting structure. This wall panel can always bemade with any type of construction material, for example, concrete,wood, melamine, fibre-reinforced cement, plastic, metal, etc. All thewalls are usually 2.40-m high, 3-m long and 10-cm thick; with all of theutility conduits and/or circuits ready to be used, in order to optimisethe process and facilitate mass production.

b) Connectors

This connector (11) and a double-sized connector (12) as a kit to builda second storey. This connector consists of a square tubular structure,with holes in predetermined positions that allow for the synchronisedassembly of the structure so that by using this connector plus thedouble-sized one, it is possible to secure the floor grid, the columnsof one and two floors, and the perimeter frames. There is also thepossibility of removing the entire upper grid, either in the ceiling ofthe second floor for that case, or in the upper grid in the case ofone-storey buildings. This possibility becomes obvious and simple sincethe wall connector is designed for said purpose, so the two options arejointly offered.

c) Water Network System Part

This part of the system kit (20) is a box that houses or holds acold-water pipe network (22) and a hot water pipe network (21) inparallel form, where the upper pipe has an outlet downward diversion onthe left side, which is used as network supply; and the lower pipe hasthe same arrangement, but the other way around. This system is designedto be coupled to the wall panel and also has 4 outlets that go into thewall panel. These outlets have threaded “tee” ends (23) ready to insertsome nipples which are also threaded and shall go through the wallpanels in case it is required to use this part. This water system partis also universal and meets any need.

e) Floor Parts and Floor Fasteners

Thanks to the universal system altogether, these parts have allowed usto cut these floor plates (17) (18) (19) in only three parts that have aunique and universal way to fill up the spaces among four columns. Inour system, these columns are always identical and offer the ability toalways create identical spaces. For this, the unique parts that supportthis floor (15) have been created, thanks to the system as a whole.

Example of Embodiment

A prototype has been manufactured to test the functionality of thesystem or process as a whole.

What is claimed is:
 1. A modular construction system consisting of: a)at least one wall panel (1) interconnected with another wall panel; andb) at least one wall connector (11) uniting the wall panels; distinctivein that the wall panel (1) consists of a pair of horizontal boxes (3),wherein the ends of the horizontal box (3) are interconnected with apair of vertical boxes (2); the wall connector (11) consists of a hollowsquare tubular structure with a groove in the upper end; and alsoconsists of at least one upper tie-down strip (5) interconnected withthe wall panel and a lower tie-down strip (8) interconnected with thevertical boxes (2).
 2. A modular construction system according to claim1, wherein for each pair of vertical boxes (2) at least one door (9),one window (10), another vertical box (4) and combinations thereof aremounted.
 3. A modular construction system according to claim 1, whereineach wall panel (1) contains inside power wiring (6), and each wallpanel has an electrical conduit for power wiring (6) and its respectiveoutlet/switch (7).
 4. A modular construction system according to claim1, wherein there is a water system (20) interconnected with one of thewalls (1), consisting of an independent box (20) that incorporates a hotwater pipe network (21) and a cold-water pipe network (22) in parallelform, and their respective outlets into the wall panel interior throughtee connectors (23).
 5. A modular construction system according to claim1, wherein there are floor parts (17,18,19) all interconnected to thewall connectors (11) to fill the spaces between the four columns formedamong the four connectors respectively.
 6. A modular construction systemaccording to claim 1, wherein the wall connector (11) is interconnectedwith another wall connector (12) for the building of a second floor. 7.A modular construction system according to claim 1, wherein there is atleast one connector fastening angle (13) to interconnect with theconnectors (11, 12), secured by fastening devices (16).
 8. A modularconstruction system according to claim 1, wherein there is at least oneconnector fastening angle (14) to interconnect with the end connectorsof the construction system.
 9. A modular construction system accordingto claim 1, wherein there is in addition one floor fastening angle (15)to support the floor parts (17, 18, 19).
 10. A modular constructionsystem according to claim 1, wherein the horizontal boxes (3), thevertical boxes (4), the wall connectors (11,12), the upper tie-downstrip (5), the lower tie-down strip (8), the floor parts (17,18,19) andthe fastening angles (13,14,15) have holes in their outer surface toensure interconnection to each other.